Method and Apparatus for Bonding Substrates

ABSTRACT

The present disclosure relates to methods for bonding first and second substrates together with tackifier free adhesives. The tackifier free adhesive may be applied to the second substrate to define an adherence zone. The first substrate is positioned on the adherence zone of the second substrate to define a first region and a second region of the adherence zone. In the first region, the tackifier free adhesive is positioned between the first substrate and the second substrate. In the second region, the tackifier free adhesive may or may not be positioned between the first substrate and the second substrate, and may not bond the first substrate with the second substrate. Thus, tackifier free adhesive may be applied to the second substrate to create an adherence zone defining a relatively large area that permits the placement of the first substrate thereon without the need to completely cover the adherence zone.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/534,067, filed on Aug. 7, 2019, which claims the benefit of U.S.Provisional Application No. 62/718,071, filed on Aug. 13, 2018, theentirety of which is incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for bondingsubstrates that may be used as components of absorbent articles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of disposable absorbent articles,such as diapers, sanitary napkins, and pant liners, may be assembled byadding components to and otherwise modifying advancing, continuous websof material. Webs of material and component parts used to manufacturediapers may include: backsheets, topsheets, absorbent cores, frontand/or back ears, fastener components, and various types of elastic websand components such as leg elastics, barrier leg cuff elastics, andwaist elastics. Webs of material and component parts used to manufacturesanitary napkins and/or panty liners may include: backsheets, topsheets,secondary topsheets, absorbent core components, release paper wrappers,and the like. Once the desired component parts are assembled, theadvancing web(s) and component parts are subjected to a final knife cutto separate the web(s) into discrete absorbent articles. The absorbentarticles may also sometimes be folded and/or individually wrapped.

When manufacturing absorbent articles, various components and/oradvancing webs of material may be bonded together in various ways, suchas with adhesives and/or mechanical bonding techniques. Some bondingoperations may bond substrates together with hot melt adhesives thatremain tacky even after the adhesives have cooled. However, utilizingsuch adhesives to bond discrete parts with other substrates can presentvarious challenges in some types of assembly operations. For example, insome assembly operations, a first continuous substrate may be cut intodiscrete parts, such as waist bands for example. In turn, the discretewaistbands, may be bonded with a continuous substrate, such as atopsheet. With continued reference to a waistband and topsheet bondingoperation as an example illustration, adhesive may be applied to eitheror both the discrete waistband and the topsheet. When applying adhesiveto the discrete waistband prior to combining with the topsheet, appliedadhesive may migrate from the waistband and contaminate materialhandling equipment, such as such as knives, drums, and conveyancedevices utilized to place the waistband on the topsheet. Suchcontaminating adhesive may also migrate to other substrates andcomponents of the assembled article. Instead of applying adhesive to thewaistband, adhesive may be applied to the topsheet before combining withthe waistband. As such, the adhesive may be applied to the topsheet indiscrete patches that are sized to correlate or match with the size ofthe waistband. Such an operation requires very precise placement of thewaistband on the discrete patches of adhesive. Misplacement of thewaistbands on the adhesive may lead to portions of the waistbands beingunbonded and may also lead to areas of exposed adhesive. In turn,exposed adhesive that remains tacky can act to unintentionally bondother components together. For example, in subsequent assemblyoperations, the combined waistband and topsheet may be combined withother advancing substrates and/or components to create discreteabsorbent articles that are folded and packaged. As such, the absorbentarticle may become bonded to itself in the folded configuration.

In an attempt to avoid the above described negative affects resultingfrom exposed tacky adhesive in an assembled product, adhesives may beapplied in areas that are smaller than the discrete part to be bonded.For example, adhesive may be applied to only central portions ofdiscrete waistband before combining with a topsheet. In anotherscenario, adhesive may be applied to the topsheet in discrete patchesthat are relatively smaller than the size of the waistband. In turn,only the central region of a waistband may be bonded with the topsheet.As such, perimeter edges of the waistband may remain unbonded and loose.Such unbonded edges may be aesthetically unpleasing and may lead toundesired tearing and/or separation of the waistband during product use.

Consequently, it would be beneficial to provide a method and apparatusfor bonding substrates to other substrates with adhesives appliedthereto so as to bond entire areas of the substrates without thenegative effects associated with exposed adhesives that remain tackyduring subsequent assembly operations.

SUMMARY OF THE INVENTION

In one form, a method of bonding substrates comprises: providing a firstsubstrate comprising a first surface and an opposing second surface;providing a second substrate comprising a first surface and an opposingsecond surface; applying a tackifier free adhesive to the first surfaceof the second substrate to define an adherence zone; positioning thefirst substrate on the adherence zone of the second substrate to definea first region of the adherence zone wherein the tackifier free adhesiveis positioned between the second surface of the first substrate and thefirst surface of the second substrate, and a second region of theadherence zone wherein the tackifier free adhesive is not positionedbetween the second surface of the first substrate and the first surfaceof the second substrate; and pressing the first substrate and the secondsubstrate against each other.

In another form, a method for making a laminate comprises: providing adiscrete first substrate comprising a first surface and an opposingsecond surface, the discrete first substrate further comprising a firstarea; advancing a continuous second substrate comprising a first surfaceand an opposing second surface; heating a tackifier free adhesive;subsequent to heating, applying the tackifier free adhesive to the firstsurface of the continuous substrate to define an adherence zonecomprising a second area, wherein the second area is greater than thefirst area; forming a laminate by positioning the discrete firstsubstrate on the adherence zone on the continuous second substrate todefine a first region of the adherence zone wherein the tackifier freeadhesive is positioned between the second surface of the first substrateand the first surface of the second substrate, and a second region ofthe adherence zone wherein the tackifier free adhesive is not positionedbetween the second surface of the first substrate and the first surfaceof the second substrate; and pressing the discrete first substrate andthe continuous second substrate against each other to force thetackifier free adhesive into the first substrate and the secondsubstrate.

In yet another form, an absorbent article comprises: a laminatecomprising: a first nonwoven comprising a first surface and an opposingsecond surface; a second nonwoven comprising a first surface and anopposing second surface; a tackifier free adhesive positioned on thefirst surface of the second nonwoven defining an adherence zone; whereinthe first nonwoven is positioned on the adherence zone of the secondnonwoven to define a first region of the adherence zone wherein thetackifier free adhesive bonds the first nonwoven with the secondnonwoven and is positioned between the second surface of the firstnonwoven and the first surface of the second nonwoven, and a secondregion of the adherence zone wherein the first nonwoven is not bondedwith the second nonwoven; and wherein a portion of the tackifier freeadhesive in the first region of the adherence zone is intermeshed withfibers between the first surface and the second surface of the secondnonwoven and intermeshed with fibers between the first surface and thesecond surface of the first nonwoven.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a partially cut away plan view of an absorbent article in theform of a taped diaper that may include one or more substrates bonded inaccordance with the present disclosure with the portion of the diaperthat faces away from a wearer oriented towards the viewer.

FIG. 1B is a plan view of the absorbent article of FIG. 1A that mayinclude one or more substrates bonded in accordance with the presentdisclosure with the portion of the diaper that faces toward a weareroriented towards the viewer.

FIG. 2A is a front perspective view of an absorbent article that mayinclude one or more substrates bonded in accordance with the presentdisclosure.

FIG. 2B is a front view of the absorbent article of FIG. 2A.

FIG. 2C is a rear view of the absorbent article of FIG. 2A.

FIG. 3 is a schematic side view of an apparatus for assembling alaminate with a tackifier free adhesive.

FIG. 4 is a left side view of an apparatus for assembling a laminatewith a tackifier free adhesive.

FIG. 5A is a side view of a first configuration of an advancing firstsubstrate, second substrate, adherence zones, and laminate taken alongthe sectional line 5A-5A of FIG. 4 .

FIG. 5B is a side view of a second configuration of advancing firstsubstrates, second substrate, adherence zones, and laminate taken alongthe sectional line 5B-5B of FIG. 4 .

FIG. 5C is a side view of a third configuration of advancing firstsubstrates, second substrates, adherence zones, and laminate taken alongthe sectional line 5C-5C of FIG. 4 .

FIG. 6 is a left side view of an apparatus for assembling a laminatewith a tackifier free adhesive.

FIG. 7A is a side view of a first configuration of an advancing firstsubstrate, second substrate, adherence zones, and laminate taken alongthe sectional line 7A-7A of FIG. 6 .

FIG. 7B is a side view of a second configuration of advancing firstsubstrates, second substrate, adherence zones, and laminate taken alongthe sectional line 7B-7B of FIG. 6 .

FIG. 8 is a schematic illustration of a diaper pant assembly processwith elastomeric laminates.

FIG. 8A is a schematic illustration of a second diaper pant assemblyprocess with elastomeric laminates.

FIG. 9 is a detailed view of a side seam.

FIG. 10 is a side view of the side seam taken along the sectional line10-10 of FIG. 9 .

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Absorbentarticles can comprise sanitary napkins, tampons, panty liners,interlabial devices, wound dressings, wipes, disposable diapersincluding taped diapers and diaper pants, inserts for diapers with areusable outer cover, adult incontinent diapers, adult incontinent pads,and adult incontinent pants. The term “disposable” is used herein todescribe absorbent articles which generally are not intended to belaundered or otherwise restored or reused as an absorbent article (e.g.,they are intended to be discarded after a single use and may also beconfigured to be recycled, composted or otherwise disposed of in anenvironmentally compatible manner).

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335,5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041,6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016,6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887A1; 2013/0211356 A1; and 2013/0306226 A1, all of which are incorporatedby reference herein.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

The term “feminine hygiene articles” refers to disposable absorbentarticles used by women for catamenial protection. Such feminine hygienearticles may include sanitary napkins, tampons, interlabial products,incontinence devices, and pantiliners. Non-limiting examples of pantyliners and sanitary napkins include those disclosed in U.S. Pat. Nos.4,324,246; 4,463,045; 4,342,314; 4,556,146; 4,589,876; 4,687,478;4,950,264; 5,009,653; 5,267,992; and 6,004,893.

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. In some configurations, a nonwoven may comprise a polyolefin basednonwoven, including but not limited to nonwovens having polypropylenefibers and/or polyethylene fibers and/or bicomponent fibers comprising apolyolefin. Nonlimiting examples of suitable fibers include spunbond,spunlaid, meltblown, spunmelt, solvent-spun, electrospun, carded, filmfibrillated, melt-film fibrillated, air-laid, dry-laid, wet-laid staplefibers, and other nonwoven web materials formed in part or in whole ofpolymer fibers as known in the art, and workable combinations thereof.Nonwovens do not have a woven or knitted filament pattern. It is to beappreciated that nonwovens having various basis weights can be used inaccordance with the methods herein. For example, some nonwovens may havea basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25 gsm,25 gsm, 40 gsm, or 65 gsm. Some nonwovens may have basis weight of about8 gsm to about 65 gsm, specifically reciting all 1 gsm increments withinthe above-recited ranges and all ranges formed therein or thereby.

It is to be appreciated that films having various basis weights can beused in accordance with the methods herein. For example, some films mayhave a basis weight of at least about 8 gsm, 12 gsm, 16 gsm, 20 gsm, 25gsm, 25 gsm, 40 gsm, or 60 gsm. Some films may have basis weight ofabout 8 gsm to about 60 gsm, specifically reciting all 1 gsm incrementswithin the above-recited ranges and all ranges formed therein orthereby.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “tackifier free adhesive” is used herein to refer to anadhesive composition comprising a polymer and/or a copolymer, whereinthe adhesive composition if free of or devoid of tackifiers. Examples ofsuch tackifier free adhesives are disclosed in U.S. Patent ApplicationNos. 62/660,338; 62/660,343; 62/660,353; 62/660,357; and 62/660,359, allof which are incorporated by reference herein.

“Devoid of,” “free of,” and the like, as those terms are used herein,means that the adhesive composition does not have more than traceamounts of background levels of a given material, ingredient, orcharacteristic following these qualifiers; the amount of the material oringredient does not cause harm or irritation that consumers typicallyassociate with the material or ingredient; or the material or ingredientwas not added to the adhesive composition intentionally. In someapplications, “devoid of” and “free of” can mean there is no measurableamount of the material or ingredient. For example, the adhesivecomposition in some forms can contain no measurable amount of atackifier.

The term “tackifier” means those conventional tackifier resins commonlyavailable in the adhesive art and industry that are used in typical hotmelt adhesives, Examples of conventional tackifier resins includealiphatic hydrocarbon resins, aromatic modified aliphatic hydrocarbonresins, hydrogenated poly-cyclopentadiene resins, poly-cyclopentadieneresins, gum rosins, gum rosin esters, wood rosins, wood rosin esters,tall oil rosins, tall oil rosin esters, poly-terpene, aromatic modifiedpoly-terpene, terpene-phenolic, aromatic modified hydrogenatedpoly-cyclopentadiene resins, hydrogenated aliphatic resins, hydrogenatedaliphatic aromatic resins, hydrogenated terpene and modified terpene,and hydrogenated rosin esters.

Aspects of the present disclosure relate to methods and apparatuses forbonding substrates used in absorbent articles, and in particular,methods and apparatuses for bonding a first substrate together a secondsubstrate with hot melt adhesives that do not include tackifiers. Suchtackifier free adhesives are relatively less tacky when cooled to asolid state. As discussed below, the first substrate comprises a firstsurface and an opposing second surface, and the second substratecomprises a first surface and an opposing second surface. The tackifierfree adhesive may be applied to the first surface of the secondsubstrate to define an adherence zone. The first substrate is positionedon the adherence zone of the second substrate to define a first regionand a second region of the adherence zone to form a laminate. In thefirst region, the tackifier free adhesive is positioned between thesecond surface of the first substrate and the first surface of thesecond substrate. In the second region, the tackifier free adhesive isnot positioned between the second surface of the first substrate and thefirst surface of the second substrate. In addition, the first substrateand the second substrate may be pressed against each other in the firstregion of the adherence zone to help the tackifier free adhesive topenetrate into the first substrate and the second substrate. When thefirst and second substrates are configured as nonwovens, penetration ofthe tackifier free adhesive into the nonwovens may help strengthen bondtherebetween by enabling the tackifier free adhesive to intermesh withand bond with fibers within the nonwovens. The laminate may then besubjected to additional manufacturing and converting operations, such ascombining, folding, and/or cutting operations, during assembly of anabsorbent article. As the tackifier free adhesive cools in the adherencezone, the exposed tackifier free adhesive in the second region is lesslikely to unintentionally and undesirably cause the second substrate tobecome bonded to itself or other substrates and/or machinery during suchsubsequent assembly operations. Thus, the methods herein permit theapplication of the tackifier free adhesive to the second substrate tocreate an adherence zone defining a relatively large area that permitsthe placement of the first substrate thereon without the need tocompletely cover the adherence zone.

It is to be appreciated that the systems and methods disclosed hereinare applicable to work with various types of converting processes and/ormachines, such as for example, absorbent article manufacturing andassembly processes. The methods and apparatuses are discussed below inthe context of manufacturing diapers. And for the purposes of a specificillustration, FIGS. 1A and 1B show an example of an absorbent article100 that may be assembled in accordance with the methods and apparatusesdisclosed herein. In particular, FIG. 1A shows one example of a planview of an absorbent article 100 configured as a taped diaper 100T, withthe portion of the diaper that faces away from a wearer oriented towardsthe viewer. And FIG. 1B shows a plan view of the diaper 100 with theportion of the diaper that faces toward a wearer oriented towards theviewer. The taped diaper 100T shown in FIGS. 1A and 1B includes anabsorbent chassis 102, first and second rear side panels 104 and 106;and first and second front side panels 108 and 110.

As shown in FIGS. 1A and 1B, the diaper 100 and the chassis 102 eachinclude a first waist region 116, a second waist region 118, and acrotch region 119 disposed intermediate the first and second waistregions. The first waist region 116 may be configured as a front waistregion, and the second waist region 118 may be configured as back waistregion. In some embodiments, the length of each of the front waistregion, back waist region, and crotch region may be ⅓ of the length ofthe absorbent article 100. The absorbent article may also include alaterally extending front waist edge 120 in the front waist region 116and a longitudinally opposing and laterally extending back waist edge122 in the back waist region 118. To provide a frame of reference forthe present discussion, the diaper 100T in FIGS. 1A and 1B is shown witha longitudinal axis 124 and a lateral axis 126. The longitudinal axis124 may extend through a midpoint of the front waist edge 120 andthrough a midpoint of the back waist edge 122. And the lateral axis 126may extend through a midpoint of a first longitudinal or right side edge128 and through a midpoint of a second longitudinal or left side edge130.

As shown in FIGS. 1A and 1B, the diaper 100 includes an inner, bodyfacing surface 132, and an outer, garment facing surface 134. And thechassis 102 may include a backsheet 136 and a topsheet 138. The chassis102 may also include an absorbent assembly 140, including an absorbentcore 142, disposed between a portion of the topsheet 138 and thebacksheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs, anelastic waist region, and/or flaps, e.g., side panels and/or ears, toenhance the fits around the legs and waist of the wearer, to enhance thefit around the legs of the wearer.

As shown in FIGS. 1A and 1B, the periphery of the chassis 102 may bedefined by the first longitudinal side edge 128, a second longitudinalside edge 130, a first laterally extending end edge 144 disposed in thefirst waist region 116, and a second laterally extending end edge 146disposed in the second waist region 118. Both side edges 128 and 130extend longitudinally between the first end edge 144 and the second endedge 146. As shown in FIG. 1A, the laterally extending end edges 144 and146 may form a portion of the laterally extending front waist edge 120in the front waist region 116 and a portion of the longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. The distance between the first lateral end edge 144 and thesecond lateral end edge 146 may define a pitch length, PL, of thechassis 102. When the diaper 100 is worn on the lower torso of a wearer,the front waist edge 120 and the back waist edge 122 may encircle aportion of the waist of the wearer. At the same time, the side edges 128and 130 may encircle at least a portion of the legs of the wearer. Andthe crotch region 119 may be generally positioned between the legs ofthe wearer with the absorbent core 142 extending from the front waistregion 116 through the crotch region 119 to the back waist region 118.

It is to also be appreciated that a portion or the whole of the diaper100 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 100 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, the user of the diaper 100, including a chassis 102 having aparticular size before extension, to extend the front waist region 116,the back waist region 118, or both waist regions of the diaper 100and/or chassis 102 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the diaper 100 may include a backsheet 136. Thebacksheet 136 may also define the outer surface 134 of the chassis 102.The backsheet 136 may be impervious to fluids (e.g., menses, urine,and/or runny feces) and may be manufactured in part from a thin plasticfilm, although other flexible liquid impervious materials may also beused. The backsheet 136 may prevent the exudates absorbed and containedin the absorbent core from wetting articles which contact the diaper100, such as bedsheets, pajamas and undergarments. The backsheet 136 mayalso comprise a woven or nonwoven material, polymeric films such asthermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).The backsheet may also comprise an elastomeric film. An examplebacksheet 136 may be a polyethylene film having a thickness of fromabout 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Exemplarypolyethylene films are manufactured by Clopay Corporation of Cincinnati,Ohio, under the designation BR-120 and BR-121 and by Tredegar FilmProducts of Terre Haute, Ind., under the designation XP-39385. Thebacksheet 136 may also be embossed and/or matte-finished to provide amore clothlike appearance. Further, the backsheet 136 may permit vaporsto escape from the absorbent core (i.e., the backsheet is breathable)while still preventing exudates from passing through the backsheet 136.The size of the backsheet 136 may be dictated by the size of theabsorbent core 142 and/or particular configuration or size of the diaper100.

Also described above, the diaper 100 may include a topsheet 138. Thetopsheet 138 may also define all or part of the inner surface 132 of thechassis 102. The topsheet 138 may be compliant, soft feeling, andnon-irritating to the wearer's skin. It may be elastically stretchablein one or two directions. Further, the topsheet 138 may be liquidpervious, permitting liquids (e.g., menses, urine, and/or runny feces)to penetrate through its thickness. A topsheet 138 may be manufacturedfrom a wide range of materials such as woven and nonwoven materials;apertured or hydroformed thermoplastic films; apertured nonwovens,porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Woven and nonwoven materials may comprise naturalfibers such as wood or cotton fibers; synthetic fibers such aspolyester, polypropylene, or polyethylene fibers; or combinationsthereof. If the topsheet 138 includes fibers, the fibers may bespunbond, carded, wet-laid, meltblown, hydroentangled, or otherwiseprocessed as is known in the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet substantiallynon-absorbent, and have a reduced tendency to allow fluids to pass backthrough and rewet the wearer's skin. Exemplary apertured films mayinclude those described in U.S. Pat. Nos. 5,628,097; 5,916,661;6,545,197; and 6,107,539.

As mentioned above, the diaper 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIGS. 1A and1B, the absorbent assembly 140 may have a laterally extending front edge148 in the front waist region 116 and may have a longitudinally opposingand laterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprise primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156 and an elasticized waistband 158. It is to be appreciated thatthe leg cuffs 156 can be and are sometimes also referred to as legbands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs. Theelasticized leg cuffs 156 may be configured in various ways to helpreduce the leakage of body exudates in the leg regions. Example legcuffs 156 may include those described in U.S. Pat. Nos. 3,860,003;4,909,803; 4,695,278; 4,795,454; 4,704,115; and U.S. Patent PublicationNo. 2009/0312730 A1.

The elasticized waistband 158 may provide improved fit and containmentand may be a portion or zone of the diaper 100 that may elasticallyexpand and contract to dynamically fit a wearer's waist. The elasticizedwaistband 158 may extend longitudinally inwardly from the waist edges120, 122 of the diaper toward the lateral edges 148, 150 of theabsorbent core 142. The diaper 100 may also include more than oneelasticized waistband 158, for example, having one waistband 158positioned in the back waist region 118 and one waistband 158 positionedin the front wait region 116, although other embodiments may beconstructed with a single elasticized waistband 158. The elasticizedwaistband 158 may be constructed in a number of different configurationsincluding those described in U.S. Pat. Nos. 4,515,595 and 5,151,092. Insome embodiments, the elasticized waistbands 158 may include materialsthat have been “prestrained” or “mechanically prestrained” (subjected tosome degree of localized pattern mechanical stretching to permanentlyelongate the material). The materials may be prestrained using deepembossing techniques as are known in the art. In some embodiments, thematerials may be prestrained by directing the material through anincremental mechanical stretching system as described in U.S. Pat. No.5,330,458. The materials are then allowed to return to theirsubstantially untensioned condition, thus forming a zero strain stretchmaterial that is extensible, at least up to the point of initialstretching. Examples of zero strain materials are disclosed in U.S. Pat.Nos. 2,075,189; 3,025,199; 4,107,364; 4,209,563; 4,834,741; and5,151,092.

As shown in FIG. 1B, the chassis 102 may include longitudinallyextending and laterally opposing side flaps 160 that are disposed on theinterior surface 132 of the chassis 102 that faces inwardly toward thewearer and contacts the wearer. Each side flap may have a proximal edge.The side flaps may also overlap the absorbent assembly 140, wherein theproximal edges extend laterally inward of the respective side edges ofthe absorbent assembly 152 and 154. In some configurations, the sideflaps may not overlap the absorbent assembly. It is to be appreciatedthat the side flaps may be formed in various ways, such as for example,by folding portions of the chassis 102 laterally inward, i.e., towardthe longitudinal axis 124, to form both the respective side flaps andthe side edges 128 and 130 of the chassis 102. In another example, theside flaps may be formed by attaching an additional layer or layers tothe chassis at or adjacent to each of the respective side edges and ofthe chassis. Each of the side flaps may be joined to the interiorsurface 132 of the chassis and/or the absorbent assembly in side flapattachment zones in the front waist region 116 and in side flapattachment zones in the back waist region 118. The side flaps may extendto the same longitudinal extent as the absorbent article oralternatively the side flaps may have a longitudinal extent that is lessthan the absorbent article.

Taped diapers may be manufactured and provided to consumers in aconfiguration wherein the front waist region and the back waist regionare not fastened, pre-fastened, or connected to each other as packaged,prior to being applied to the wearer. For example, the taped diaper 100may be folded about a lateral centerline with the interior surface 132of the first waist region 116 in surface to surface contact with theinterior surface 132 of the second waist region 118 without fastening orjoining the waist regions together. The rear side panels 104 and 106and/or the front side panels 108 and 110 may also be folded laterallyinward toward the inner surfaces 132 of the waist regions 116 and 118.

The diaper 100 may also include various configurations of fasteningelements to enable fastening of the front waist region 116 and the backwaist region 118 together to form a closed waist circumference and legopenings once the diaper is positioned on a wearer. For example, asshown in FIGS. 1A and 1B, the diaper 100 may include first and secondfastening members 162, 164, also referred to as tabs, connected with thefirst and second rear side panels 104, 106, respectively. The diaper mayalso include first and second front side panels 108, 110, that may ormay not include fastening members.

With continued reference to FIGS. 1A and 1B, each side panel 104, 106and/or fastening member 162 and 164 may form a portion of or may bepermanently bonded, adhered or otherwise joined directly or indirectlyto the chassis 102 laterally inward from the side edge 128 and 130, inone of the front waist region 116 or the back waist region 118.Alternatively, the fastening members 162, 164 may form a portion of ormay be permanently bonded, adhered or otherwise joined directly orindirectly to the first and second rear panels 104, 106 at or adjacentthe distal edge of the panel and/or the first and second front sidepanels 108 and 110 at or adjacent the distal edge of the side panel. Itis to be appreciated that the fastening members and/or side panels maybe assembled in various ways, such as disclosed for example, in U.S.Pat. No. 7,371,302. The fastening members 162, 164 and/or side panels104, 106, 108, 110 may also be permanently bonded or joined at oradjacent the side edges 128 and 130 of the chassis 102 in various ways,such as for example, by adhesive bonds, sonic bonds, pressure bonds,thermal bonds or combinations thereof, such as disclosed for example,U.S. Pat. No. 5,702,551.

Referring now to FIG. 1B, the first fastening member 162 and/or thesecond fastening member 164 may include various types of releasablyengageable fasteners. The first and second fastening members 162 and/or164 may also include various types of refastenable fastening structures.For example, the first and second fastening members 162 and 164 mayinclude mechanical fasteners, 166, in the form of hook and loopfasteners, hook and hook fasteners, macrofasteners, buttons, snaps, taband slot fasteners, tape fasteners, adhesive fasteners, cohesivefasteners, magnetic fasteners, hermaphroditic fasteners, and the like.Some examples of fastening systems and/or fastening members 162, 164 arediscussed in U.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060;4,946,527; 5,151,092; 5,221,274; 6,251,097; 6,669,618; 6,432,098; andU.S. Patent Publication Nos. 2007/0078427 A1 and 2007/0093769 A1.

As previously mentioned, the fastening members 162 and 164 may beconstructed from various materials and may be constructed as a laminatestructure. The fastening members 162 and 164 may also be adapted toreleasably and/or refastenably engage or connect with another portion ofthe diaper 100. For example, as shown in FIG. 1A, the diaper 100 mayinclude a connection zone 168, sometimes referred to as a landing zone,in the first waist region 116. As such, when the taped diaper 100 isplaced on a wearer, the fastening members 162 and 164 may be pulledaround the waist of the wearer and connected with the connection zone168 in the first waist region 116 to form a closed waist circumferenceand a pair of laterally opposing leg openings. It is to be appreciatedthat the connection zone may be constructed from a separate substratethat is connected with the chassis 102 of the taped diaper. In someembodiments, the connection zone may be integrally formed as part of thebacksheet 136 of the diaper 100 or may be formed as part of the firstand second front panels 108, 110, such as described in U.S. Pat. Nos.5,735,840 and 5,928,212.

As previously mentioned, absorbent articles 100 may also be configuredas diaper pants 100P having a continuous perimeter waist opening andcontinuous perimeter leg openings. For example, FIG. 2A shows aperspective view of an absorbent article 100 in the form of a diaperpant 100P in a pre-fastened configuration, and FIGS. 2B-2C show frontand rear plan views of the diaper pant 100P. The diaper pant 100P mayinclude a chassis 102 such a discussed above with reference to FIG. 1Aand a ring-like elastic belt 170 such as shown in FIG. 2A. In someembodiments, a first elastic belt 172 and a second elastic belt 174 arebonded together to form the ring-like elastic belt 170. As such, diaperpants may be manufactured with the ring-like elastic belt 174 andprovided to consumers in a configuration wherein the front waist region116 and the back waist region 118 of the chassis 102 are connected toeach other as packaged, prior to being applied to the wearer. As such,diaper pants may have a continuous perimeter waist opening 176 andcontinuous perimeter leg openings 178 such as shown in FIG. 2A.

As previously mentioned, the ring-like elastic belt 170 may be definedby a first elastic belt 172 connected with a second elastic belt 174. Asshown in FIGS. 2A-2C, the first elastic belt 172 extends between a firstlongitudinal side edge 180 a and a second longitudinal side edge 180 b.And the second elastic 174 belt extends between a first longitudinalside edge 182 a and a second longitudinal side edge 182 b. The distancebetween the first longitudinal side edge 180 a and the secondlongitudinal side edge 180 b defines a pitch length, PL, of the firstelastic belt 172, and the distance between the first longitudinal sideedge 182 a and the second longitudinal side edge 182 b defines the pitchlength, PL, of the second elastic belt 174. The first elastic belt isconnected with the first waist region 116 of the chassis 102, and thesecond elastic belt 108 is connected with the second waist region 116 ofthe chassis 102. As shown in FIGS. 2A-2C, opposing end regions of thefirst elastic belt 172 are connected with opposing end regions of thesecond elastic belt 174 at a first side seam 184 and a second side seam186 to define the ring-like elastic belt 170 as well as the waistopening 176 and leg openings 178. It is to be appreciated that thering-like elastic belt may be formed by joining a first elastic belt toa second elastic belt with permanent side seams or with openable andreclosable fastening systems disposed at or adjacent the laterallyopposing sides of the belts.

As previously mentioned, absorbent articles may be assembled withvarious components that may constructed with the laminates describedherein. Thus, in the context of the previous discussion, the apparatusesand methods herein may be used to bond substrates configured ascontinuous substrates and/or discrete components of an absorbent article100. For example, the apparatuses and methods herein may be utilized tobond substrates to create laminates to be used as or with any of thetopsheet 138; backsheet 136; absorbent core 140; leg cuffs 156; waistfeature 158; side panels 104, 106, 108, 110; connection zones 168;fastening elements 162, 164, 166, and/or belts before, during, and/orafter the manufacture of an absorbent article 100.

It is to be appreciated that the systems and methods disclosed hereinare applicable to work with various types of converting processes and/ormachines. For example, FIG. 3 shows a schematic representation of aconverting process including a bonding apparatus or system 300 thatbonds a first substrate 200 with a second substrate 202 to form alaminate 204. The first substrate 200 includes a first surface 206 andan opposing second surface 208. In some configurations, the firstsubstrate 200 may also be configured as a discrete piece or part thatmay be cut or otherwise separated from a continuous first substrate 201.As such, the shape of the first substrate 200 may be defined by acontinuous perimeter edge 210. The second substrate 202 includes a firstsurface 212 and an opposing second surface 214. In some configurations,the second substrate 202 may be configured as a continuous secondsubstrate advancing in a machine direction MD. The second substrate 202may also define a width extending in the cross direction CD between afirst longitudinal side edge 216 and a second longitudinal side edge218.

As shown in FIG. 3 , the bonding system 300 may include an adhesiveapplicator 302. During operation, the second substrate 204 advances inthe machine direction MD. In turn, the adhesive applicator 302 depositstackifier free adhesive 400 onto the first surface 212 of the advancingsecond substrate 202 to define an adherence zone 402. The firstsubstrate 200 is positioned on the adherence zone 402 on the secondsubstrate 202 to define a first region 404 and a second region 406 ofthe adherence zone 402. In the first region 404 of the adherence zone402, the tackifier free adhesive 400 is positioned between the secondsurface 208 of the first substrate 200 and the first surface 212 of thesecond substrate 202. And in the second region 406 of the adherence zone402, the tackifier free adhesive 400 is not positioned between thesecond surface 208 of the first substrate 200 and the first surface 212of the second substrate 202.

With continued reference to FIG. 3 , the tackifier free adhesive 400 inthe second region 406 may remain exposed or otherwise uncovered by thefirst substrate 200 as the laminate 204 advances to additionaldownstream, subsequent manufacturing and converting operations, such ascombining, folding, and/or cutting operations. Such additionalsubsequent operations are represented by the dashed arrow “A” thatgenerically represents converting the laminate 204 into at least onediscrete article 203. As such, the article 203 may include exposedtackifier free adhesive 400 in the second region 406 of the adherencezone 402 wherein second substrate 202 does not unintentionally becomebonded to itself or other substrates and/or machinery during suchadditional subsequent operations. For example, FIG. 3 shows anadditional subsequent operation of folding (represented by the dashedarrow “B”) the discrete article 203 and the second substrate 202. As aresult of folding, a portion of the first surface 212 of the secondsubstrate 202 may be positioned into direct contact with the firstsurface 206 of the first substrate 200 and the second region 406 of theadherence zone 402. In turn, the tackifier free adhesive 400 does notbond the second substrate 202 and unintentionally hold the article 203in a folded state. It is to be appreciated that the discrete article 203may be in various forms and types, such as, for example, absorbentarticles including feminine hygiene articles, diapers, sanitary napkins,and panty liners. It is also to be appreciated that the tackifier freeadhesive 400 in the second region may be exposed to a wearer's skinand/or clothing during use of the article without unintentionallybonding to the wearer's skin and/or clothing.

It is to be appreciated that various process configurations may utilizedto bond a first substrate 200 and a second substrate 202 with tackifierfree adhesives to form the laminates 204 described herein. For example,FIG. 4 shows a schematic view of an example configuration of anapparatus 300 that may be utilized to form a laminate 204. The apparatus300 may include a transfer assembly 304 configured to transport firstsubstrates 200 in the form of discrete parts in a machine direction MDfrom a first position P1 to a second position P2. As shown in FIG. 4 , acontinuous first substrate 201 advances in a machine direction MD to thetransfer assembly 304. The transfer assembly 304 may include a carriersurface 306 and may be adapted to rotate about a first axis 308. Thefirst surface 206 of the advancing continuous first substrate 201engages the moving carrier surface 306 at a pick-up zone 312. As thetransfer assembly 304 is rotated about the first axis 308 to advance aportion of the continuous first substrate 201, a cutter 314 cuts adiscrete first substrate 200 from the continuous first substrate 201 atthe pick-up zone 312. It is to be appreciated that the cutter 314 may beconfigured in various ways, such as for example, a knife or a laser.

Although the transfer assembly 304 is depicted as rotating drum, it isto be appreciated that the transfer assembly may be configured invarious ways. For example, in some embodiments, the transfer assembly304 may be in the form of a conveyor belt and/or one or more drumsand/or other types of conveyance apparatuses, such as disclosed forexample in U.S. Pat. Nos. 5,025,910; 5,224,405; 5,556,504; 5,702,551;6,319,347; 6,450,321; 6,524,423; 6,550,517; 6,604,623; 6,116,317;6,649,010; 6,722,494; 7,341,087; 7,650,984; 7,770,712; 8,720,666; and9,737,442 and U.S. Patent Publication No. 2009/0294044 A1, all of whichare incorporated by reference herein. In some configurations, thetransfer assembly 304 may rotate about the first axis 308 at a constantor variable angular velocity. In some configurations, the carriersurface 306 may orbit the first axis 308 at a constant or variableangular velocity and/or at a constant or variable speed. It is also tobe appreciated that the carrier surface 306 may advance at a speed thatis equal to or greater than the advancement speed of the continuousfirst substrate 201. In some configurations wherein the continuous firstsubstrate 201 has been stretched in the machine direction beforeengaging the transfer assembly 304, the carrier surface 306 may advanceat a speed that is less than the advancement speed of the continuousfirst substrate 201. In some configurations, the carrier surface 306 mayorbit the first axis 308 at a constant or variable distance from thefirst axis 308. It is also to be appreciated that the carrier surface306 herein may be arranged with various quantities of apertures havingvarious shapes and sizes, and may be in fluid communication with avacuum system. In addition, while orbiting from the first position P1 tothe second position P2, the carrier surface 306 and the first substrate200 may also be rotated or pivoted about a second axis of rotation toplace the first substrate 200 in a second orientation.

With continued reference to FIG. 4 , the transfer assembly 304 isrotated about the first axis 308 such that the carrier surface 306 andthe first substrate 200 positioned on the carrier surface 306 orbitabout the first axis 308 from the first position P1 to the secondposition P2. The first substrate 200 is then transferred to the secondsubstrate 202 at a drop-off zone 316 to form the laminate 204. Withparticular reference to FIGS. 4 and 5A, the second substrate 202advances in the machine direction MD past the adhesive applicator 302and toward the drop-off zone 316. The adhesive applicator 302 depositstackifier free adhesive 400 on the first surface 212 of the secondsubstrate 202 to define an adherence zone 402 of the second substrate202. At the drop-off zone 316, the first substrate 200 is transferredfrom the transfer assembly 304 to position the second surface 208 of thefirst substrate 200 on the adherence zone 402. It is to be appreciatedthat the carrier surface 306 may advance at various speeds through thedrop-off zone 316 relative to the advancement speed of the secondsubstrate 202. In some configurations, the carrier surface 306 mayadvance at the same speed as the advancement speed of the secondsubstrate 202 through the drop off zone 316. In some configurations, thecarrier surface 306 may advance at a speed that is slower than theadvancement speed of the second substrate 202 through the drop off zone316.

As shown in FIGS. 4 and 5A, the adherence zone 402 of the laminate 204may include a first region 404 and a second region 406. The tackifierfree adhesive 400 is positioned between the second surface 208 of thefirst substrate 200 and the first surface 212 of the second substrate202 in the first region 404 of the adherence zone 402. And the tackifierfree adhesive 400 is not positioned between the second surface 208 ofthe first substrate 200 and the first surface 212 of the secondsubstrate 202 in the second region 406 of the adherence zone 402.

It is to be appreciated that the adherence zone 402 and the firstsubstrate 200 may have various shapes. For example, although theadherence zone 402 is generically depicted herein as defining arectangular shape on the first surface 212 of the second substrate 202,it is to be appreciated that the adherence zone 402 may have a perimeterthat defines circular, square, oval, elliptical, and various types ofother shapes that may or may not correspond with shapes defined by allor portions of the perimeter 210 of the first substrate 200. It is to beappreciated that the adherence zone 402 and the first substrate 200 mayhave the same shape or may have different shapes.

It is to be appreciated that the adherence zone 402 and the firstsubstrate 200 may have various sizes relative to each other. Forexample, as shown in FIG. 5A, the first substrate may define a firstarea A1 and the adherence zone 402 may define a second area A2. In someconfigurations, the second area A2 may be greater than the first areaA1. In some configurations, the first area A1 may be equal to the secondarea A2. It is also to be appreciated that the first substrate 200 maybe oriented relative to the second substrate 202 and/or the adherencezone 402 in various ways. For example, as shown in FIG. 5B, the firstsubstrate 200 may be oriented on the second substrate 202 such that aportion of the second surface 208 of the first substrate 200 may not beentirely positioned on the first surface 212 of the second substrate 202and/or the adherence zone 402.

It is also to be appreciated that the apparatus 300 may be configured toassemble laminates 204 with a plurality of first substrates 200 and/orsecond substrates 202 in various orientations. For example, such asshown in FIG. 5B, the laminate 204 may include a plurality of firstsubstrates 200 a, 200 b arranged in along the machine direction MD onthe first edge 216 and second edge 218, respectively, of the secondsubstrate 202 and corresponding adherence zones 402. In another example,such as shown in FIG. 5C, the laminate 204 may include second substrates202 a, 202 b separated from each other in cross direction CD with firstsubstrates 200 arranged in along the machine direction MD and partiallyposited on both the second substrates 202 a, 202 b and correspondingadherence zones 402. It is also to be appreciated that the adhesiveapplicator 302 can be configured to apply tackifier free adhesive 400 soas to define a plurality of adherence zones 402 arranged along themachine direction MD and/or cross direction on the second substrate 202,such as shown for example in FIGS. 5A-5C. In some configurations, theadhesive applicator 302 may be configured to apply tackifier freeadhesive 400 either or both the first substrate 200 and the secondsubstrate 202.

The apparatuses 300 herein may also be configured in various ways tohelp enhance the bonding between the first and second substrates 200,202 in the adherence zone 402. In some configurations, such as shown inFIG. 4 , the first substrate 200 and/or the second substrate 202 mayinclude nonwoven layers that are combined to form the laminate 204. Inturn, the laminate 204 may advance through a nip 318 that is adapted topress first substrate 200 together with the second substrate 202 in thefirst region 404 of the adherence zone 402 to help the tackifier freeadhesive 400 to penetrate into the first and second substrates 200, 202.When the first and second substrates 200, 202 include nonwoven layers,penetration of the tackifier free adhesive into the nonwovens may causethe tackifier free adhesive to intermesh with and bond with fiberswithin the nonwovens to help strengthen bonds therebetween. For example,with configuration shown in FIG. 4 , the nip 318 may defined between apressing surface 320 and the carrier surface 306. As the first substrate200 is transferred from the transfer assembly 304 to the secondsubstrate 202, the pressure is exerted on the second surface 214 of thesecond substrate 202 by pressing surface 320 and on the first surface206 of the first substrate 200 by the carrier surface 306. In turn, thepressure exerted on the first and second substrates 200, 202 may forcethe tackifier free adhesive 400 in the adherence zone 402 through thefirst surface 212 of the second substrate 202 and through the secondsurface 208 of the first substrate 200. As such, a portion of thetackifier free adhesive 400 in the first region 404 of the adherencezone 402 may become intermeshed with fibers between the first surface212 and the second surface 214 of the second substrate 202 andintermeshed with fibers between the first surface 206 and the secondsurface 208 of the first substrate 200.

As shown in FIG. 4 , the pressing surface 320 may be defined by an outercircumferential surface 322 of a drum 324, wherein the drum 324 may beadapted to rotate about a second axis of rotation 326. It is to beappreciated that the pressing surface 320 may be configured in variousways. For example, the pressing surface 320 may be associated withvarious types of apparatuses, such as for example, a rotating bump roll,an oscillating tamper, and/or various types of configurations such asdisclosed in U.S. Pat. Nos. 4,576,600; 6,494,244; 7,452,436; 7,640,962;7,811,403; and 9,168,182; and U.S. Patent Publication No. U.S. PatentPublication No. 2009/0294044 A1, all of which are incorporated byreference herein. Although FIG. 4 depicts the nip 318 as being locatedand defined between the carrier surface 306 of the transfer assembly 304and the pressing surface 320 of the drum 324, it is to be appreciatedthat the apparatus 300 may be configured with one or more nips 320positioned downstream of the drop off zone 316 adapted to press thefirst and second substrates 200, 202 against each other in the adherencezone 402. Such nips may be configured in various ways and may be definedbetween various types of apparatuses, such as discussed herein.

With reference to FIGS. 3 and 4 , it is to be appreciated that theadhesive applicator 302 may be configured to apply the tackifier freeadhesive 400 in various ways. For example, the adhesive applicator maybe configured as a slot coating applicator or a meltblowing applicator.In some configurations, the tackifier free adhesive 400 may be heatedbefore reaching the adhesive applicator 302 and/or may be heated whileflowing through the adhesive applicator 302.

The apparatuses 300 herein may include one or more cooling apparatuses328, generically represented in FIG. 4 by a dashed rectangle, adaptedremove heat energy from the first region 404 and/or the second region406 of the adherence zone 402. It is to be appreciated that such coolingapparatuses 328 may be configured in various ways. In someconfigurations, the cooling apparatus 328 may include a heat exchanger,such as a heat sink. For example, the apparatus 300 may be configured toadvance the laminate 204 to a cooling apparatus 328 configured as one ormore chill rolls, wherein the laminate 204 may partially wrap around acooling surface of a chill roll. In some configurations, the coolingapparatus 328 may include a device, such as a fan or blower, moves airor other gas along the second surface 202 of the second substrate 202and/or the first surface 206 of the first substrate 200 and the firstsurface 212 of the second substrate 202 to remove heat energy from theadherence zone 402 with convection. Although the cooling apparatus 328schematically represented in FIG. 4 is adjacent the second surface 214of the second substrate 202, it is to be appreciated that the coolingapparatus 328 may be configured with components that are in closeproximity with or in contact with the first surface 212 and/or secondsurface 214 of the second substrate 202 and/or the first surface 206 ofthe first substrate 200.

As previously mentioned, the apparatuses and methods herein may also beused to bond substrates configured as continuous substrates. Forexample, FIG. 6 shows a schematic view of an example configuration of anapparatus 300 that may utilize a tackifier free adhesive 400 to bond acontinuous first substrate 201 with a continuous second substrate 202 toform a laminate 204. The apparatus 300 may include a transfer assembly304, such as described above, to transport the first substrate 201 in amachine direction MD from a first position P1 to a second position P2.As shown in FIG. 6 , a continuous first substrate 201 advances in amachine direction MD to the transfer assembly 304. The first surface 206of the advancing continuous first substrate 201 engages the movingcarrier surface 306 at a pick-up zone 312. With continued reference toFIG. 6 , the transfer assembly 304 is rotated about the first axis 308such that the carrier surface 306 and the continuous first substrate 201positioned on the carrier surface 306 orbit about the first axis 308from the first position P1 to the second position P2. The continuousfirst substrate 201 is then transferred to the continuous secondsubstrate 202 at a drop-off zone 316 to form the laminate 204.

With particular reference to FIGS. 6 and 7A, the continuous secondsubstrate 202 advances in the machine direction MD past the adhesiveapplicator 302 and toward the drop-off zone 316. The adhesive applicator302 deposits tackifier free adhesive 400 on the first surface 212 of thesecond substrate 202 to define an adherence zone 402 of the secondsubstrate 202. At the drop-off zone 316, the continuous first substrate201 is transferred from the transfer assembly 304 to position the secondsurface 208 of the continuous first substrate 201 on the adherence zone402. As shown in FIGS. 6 and 7A, the adherence zone 402 of the laminate204 may include a first region 404 and a second region 406. Thetackifier free adhesive 400 is positioned between the second surface 208of the continuous first substrate 201 and the first surface 212 of thecontinuous second substrate 202 in the first region 404 of the adherencezone 402. And the tackifier free adhesive 400 is not positioned betweenthe second surface 208 of the continuous first substrate 201 and thefirst surface 212 of the continuous second substrate 202 in the secondregion 406 of the adherence zone 402. As discussed above, it is to beappreciated that the adherence zone 402 and the continuous firstsubstrate 201 may have various shapes. For example, although theadherence zone 402 is generically depicted herein as defining acontinuous rectangular shape on the first surface 212 of the secondsubstrate 202, it is to be appreciated that the adherence zone 402 mayhave edges that defines circular, square, oval, elliptical, and varioustypes of other shapes that may or may not correspond with shapes definedby all or portions of edges of the continuous first substrate 201. It isto be appreciated that the adherence zone 402 and the continuous firstsubstrate 201 may have edges having the same shapes or may havedifferent shapes.

It is also to be appreciated that the continuous first substrate 201 maybe oriented relative to the second substrate 202 and/or the adherencezone 402 in various ways. For example, as shown in FIG. 7B, thecontinuous first substrate 201 may be oriented on the second substrate202 such that a portion of the second surface 208 of the first substrate201 may not be entirely positioned on the first surface 212 of thesecond substrate 202 and/or the adherence zone 402. In addition, it isalso to be appreciated that the apparatus 300 may be configured toassemble laminates 204 with a plurality of continuous first substrates201 and/or continuous second substrates 202 in various orientations. Forexample, such as shown in FIG. 7B, the laminate 204 may includecontinuous first substrates 201 a, 201 b arranged in along the machinedirection MD on the first edge 216 and second edge 218, respectively, ofthe second substrate 202 and corresponding adherence zones 402. Aspreviously mentioned, the adhesive applicator 302 may be configured toapply tackifier free adhesive 400 either or both the continuous firstsubstrate 201 and the continuous second substrate 202.

As described above, the laminates 204 discussed herein may be used as toconstruct various different components used in the manufacture ofdifferent types of absorbent articles. For example with reference toFIGS. 1A, 1B, and 2A-2C, the laminates 204 herein may be used to formall or portions of components such as: chassis 102; side panels 104,106, 108, 110; belts 172, 174; backsheets 136; topsheets 138; absorbentassembly 140; leg cuffs 156; waistband 158; side flaps 160; fasteningmembers 162, 164; and/or connection zone 168. For example, withreference to FIG. 5A, transfer assemblies 304 with carrier surfaces 306as disclosed herein may be utilized to apply first substrates 200 in theform of waistbands 158 to a second substrate 202 in the form anadvancing topsheet substrate 138. In another example, with reference toFIG. 5B, transfer assemblies 304 with carrier surfaces 306 as disclosedherein may be utilized to apply first substrates 200 a, 200 b in theform of side panels 104, 106, 108, 110 to a second substrate 202 in theform an advancing topsheet substrate 138 and/or advancing backsheetsubstrate 136. In yet another example, with reference to FIG. 5C,transfer assemblies 304 with carrier surfaces 306 as disclosed hereinmay be utilized to apply first substrates 200 in the form of chassis 102to second substrates 202 a, 202 b in the form an advancing first belt172 and second belt 174. In still another example, with reference toFIG. 7A, transfer assemblies 304 with carrier surfaces 306 as disclosedherein may be utilized to apply continuous first substrates 201 in theform of a topsheet substrate 138 to a second substrate 202 in the forman advancing backsheet substrate 136. In yet another example, withreference to FIG. 7B, transfer assemblies 304 with carrier surfaces 306as disclosed herein may be utilized to apply continuous first substrates201 in the form of leg cuffs 156 to a second substrate 202 in the forman advancing topsheet substrate 138.

In another example, the processes herein may be utilized in assemblinglaminates 204 to form side seams 184, 186 on diaper pants 100P, such asdescribed above with reference to FIGS. 2A-2C. For example, as describedbelow with reference to FIGS. 8-10 , tackifier free adhesive 400 may beused to connect opposing end regions of the first elastic belt 172 withopposing end regions of the second elastic belt 174 at a first side seam184 and a second side seam 186 to define the ring-like elastic belt 170as well as the waist opening 176 and leg openings 178.

As shown in FIG. 8 , when assembling diaper pants 100P, the firstsubstrate 201 may be in the form of a first elastic belt laminate 172 a,and the second substrate 202 may be in the form of a second elastic beltlaminate 174 a. The first elastic belt laminate 172 a and the secondelastic belt laminate 174 a may be separated from each other in thecross direction CD and may be connected with each other with a pluralityof chassis 102 intermittently spaced along the machine direction MD. Asalso illustrated in FIG. 8 , tackifier free adhesive 400 may be appliedto the second surface 208 of the first substrate 202 to define adherencezones 402. The adherence zones 402 may be in the form of discrete zonespositioned between adjacent chassis 102. In some configurations, theadherence zones 402 may extend continuously along the machine directionMD.

With continued reference to FIG. 8 , during subsequent assemblyoperations, the chassis 102 may be folded (represented by the dashedarrow “A”) so as to position the second surface 208 of the firstsubstrate 201 into a facing relationship with the first surface 212 ofthe second substrate 202. Pressure may also be applied to the firstsubstrate 201 and the second substrate 202 in the adherence zones 402 tohelp the tackifier free adhesive 400 to penetrate into and/or bond thefirst and second substrates 201, 202 together to form a laminate 204.Subsequently, discrete diaper pants 100P may be formed by separating thefirst and second substrates 201, 202 into first and second belts 172,174 by cutting along the cross direction CD through the adherence zones402. As such, the adherence zones 402 may be divided to define first andsecond adherence zones 402 a, 402 b that may correspond with first andsecond side seams 184, 186, respectively. It is to be appreciated thatinstead of having an adherence zone 402 that is subsequently dividedinto first and second adherence zones 402 a, 402 b, the tackifier freeadhesive 400 may be applied so as to define the discrete first andsecond adherence zones 402 a, 402 b, such as shown for example in FIG.8A. As such, the first and second substrates 201, 202 cut along thecross direction CD between the first and second adherence zones 402 a,402 b. It is also to be appreciated that the tackifier free adhesive 400may be applied to either or both the first and second substrates 201,202.

Referring now to FIGS. 8, 9, and 10 , at the side seams 184, 186, thefirst substrate 201 may be bonded with the second substrate 202 todefine a first region 404 and a second region 406 of the adherence zones402 a, 402 b. FIGS. 9 and 10 show detailed views of the first side 184,which may be a mirror image of the second side seam 186. As shown inFIGS. 9 and 10 , in the first region 404 of the adherence zone 402 a,the tackifier free adhesive 400 is positioned between and bonds thesecond surface 208 of the first substrate 201 with the first surface 212of the second substrate 202. And in the second region 406 of theadherence zone 402, the tackifier free adhesive 400 is positionedbetween and does not bond the second surface 208 of the first substrate201 with the first surface 212 of the second substrate 202. Duringsubsequent processing operations, such as folding and packaging, thetackifier free adhesive 400 in the second region 406 may not act tounintentionally bond with other components of the diaper pant 100P. Inaddition, the tackifier free adhesive 400 in the second region 406 mayalso be exposed to a wearer's skin and/or clothing during use of thearticle without unintentionally bonding to the wearer's skin and/orclothing.

It is to be appreciated that side seams may be formed with the methodsand apparatuses herein with tackifier free adhesive only, and may alsobe formed in conjunction with mechanical bonding processes. It also tobe appreciated that the methods and apparatuses herein may be adapted tooperate with various types of absorbent article assembly processes, suchas disclosed for example in U.S. Pat. Nos. 8,186,296; 9,265,672;9,248,054; and 9,730,839 and U.S. Patent Publication Nos. 2013/0255861A1; 2013/0255862 A1; 2013/0255863 A1; 2013/0255864 A1; and 2013/0255865A1.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: a first waist region, a second waist region, and a crotch region longitudinally positioned between the first waist region and the second waist region; a first belt located in the first waist region; a second belt located in the second waist region, wherein laterally opposing end regions of the first belt are connected with laterally opposing end regions of the first belt to define a waist opening; a chassis connected with and extending longitudinally between the first belt and the second belt, the chassis comprising an absorbent core positioned between a topsheet and a backsheet; a side seam comprising: a first nonwoven comprising a first surface and an opposing second surface; a second nonwoven comprising a first surface and an opposing second surface; a tackifier free adhesive positioned on the first surface of the second nonwoven defining an adherence zone; wherein the first nonwoven is positioned on the adherence zone of the second nonwoven to define a first region of the adherence zone wherein the tackifier free adhesive bonds the first nonwoven with the second nonwoven and is positioned between the second surface of the first nonwoven and the first surface of the second nonwoven, and a second region of the adherence zone wherein the first nonwoven is not bonded with the second nonwoven; and wherein a portion of the tackifier free adhesive in the first region of the adherence zone is intermeshed with fibers between the first surface and the second surface of the second nonwoven and intermeshed with fibers between the first surface and the second surface of the first nonwoven.
 2. The absorbent article of claim 1, wherein when the absorbent article is in a packaged configuration, the second region of the adherence zone is positioned in direct contact with at least one substrate surface without adhering to the at least one substrate surface.
 3. The absorbent article of claim 1, wherein when the absorbent article is in a wearing configuration, the second region of the adherence zone is positioned in direct contact with a wearer's skin or clothing without adhering to the wearer's skin or clothing.
 4. The absorbent article of claim 1, wherein the first waist region comprises a front waist region and the second waist region comprises a rear waist region.
 5. The absorbent article of claim 1, wherein the first belt comprises the first nonwoven.
 6. The absorbent article of claim 1, further comprising an openable and reclosable fastening system disposed adjacent laterally opposing sides of the first and second belts.
 7. An absorbent article comprising: a first waist region, a second waist region, and a crotch region longitudinally positioned between the first waist region and the second waist region; a first belt located in the first waist region; a second belt located in the second waist region, wherein laterally opposing end regions of the first belt are connected with laterally opposing end regions of the first belt to define a waist opening; a chassis connected with and extending longitudinally between the first belt and the second belt; a side seam comprising: a first nonwoven comprising a first surface and an opposing second surface; a second nonwoven comprising a first surface and an opposing second surface; a tackifier free adhesive positioned on the first surface of the second nonwoven defining an adherence zone; wherein the first nonwoven is positioned on the adherence zone of the second nonwoven wherein the tackifier free adhesive bonds the first nonwoven with the second nonwoven and is positioned between the second surface of the first nonwoven and the first surface of the second nonwoven; and wherein a portion of the tackifier free adhesive of the adherence zone is intermeshed with fibers between the first surface and the second surface of the second nonwoven and intermeshed with fibers between the first surface and the second surface of the first nonwoven.
 8. The absorbent article of claim 7, wherein a portion of the adherence zone is positioned in direct contact with at least one substrate surface without adhering to the at least one substrate surface.
 9. The absorbent article of claim 7, wherein when the absorbent article is in a wearing configuration, a portion of the adherence zone is positioned in direct contact with a wearer's skin or clothing without adhering to the wearer's skin or clothing.
 10. The absorbent article of claim 7, wherein the first waist region comprises a front waist region and the second waist region comprises a rear waist region.
 11. The absorbent article of claim 7, wherein the first belt comprises the first nonwoven.
 12. The absorbent article of claim 7, further comprising an openable and reclosable fastening system disposed adjacent laterally opposing sides of the first and second belts.
 13. An absorbent article comprising: a laminate comprising: a first nonwoven comprising a first surface and an opposing second surface; a second nonwoven comprising a first surface and an opposing second surface; a tackifier free adhesive positioned on the first surface of the second nonwoven defining an adherence zone; wherein the first nonwoven is positioned on the adherence zone of the second nonwoven to define a first region of the adherence zone wherein the tackifier free adhesive bonds the first nonwoven with the second nonwoven and is positioned between the second surface of the first nonwoven and the first surface of the second nonwoven, and a second region of the adherence zone wherein the first nonwoven is not bonded with the second nonwoven; and wherein a portion of the tackifier free adhesive in the first region of the adherence zone is intermeshed with fibers between the first surface and the second surface of the second nonwoven and intermeshed with fibers between the first surface and the second surface of the first nonwoven.
 14. The absorbent article of claim 13, wherein the second region of the adherence zone is positioned in direct contact with at least one substrate surface without adhering to the at least one substrate surface.
 15. The absorbent article of claim 13, wherein the second surface of the first nonwoven comprises a first area, and wherein the adherence zone comprises a second area, wherein the second area is equal to or greater than the first area.
 16. The method of claim 13, wherein the first substrate comprises one of a waist band, a connection zone, a leg cuff, an absorbent chassis, and a first elastic belt.
 17. The method of claim 16, wherein the second substrate comprises one of a topsheet, a backsheet, and a second elastic belt.
 18. The absorbent article of claim 13, wherein the second nonwoven comprises an elastic belt and wherein the first region of the adherence zone defines a side seam. 